Remote control switch



July 20, 1943. p HU-'rT 2,324,844

REMOTE CONTROL SWITCH Filed Dec. 18, 1940 7///////////////M|IllHlV////////////// m m Inventor: 1- 9, phllsp Hutt,

by Hl 's A tQrr-wey.

Patented July 20, 1943 UNITED STATES PATENT GFFICE REMOTE CONTROL SWITCH Philip Hutt, Milford, Conn., assignor to General Electric Company, a corporation of New York Application December 18, 1940, Serial No. 370,695 3 Claims. (Cl. 20o-105) My invention relates to Wiring systems, and more particularly to remotely controlled wiring systems for residence use.

An object of my invention is to provide an improved relay so incorporated into a house wiring system that the associated wiring circuit, for example, a lighting circuit, may be controlled from any one of a number of points.

Another object of my invention is to provide an improved relay of the type described which is compact and rugged and which may be readily incorporated into the existing wiring system oi a residence.

A further object of my invention is the provision oi a relay so constructed as to be mountable within an electric Junction box of the type ordinarily used in house wiring systems.

In the accompanying drawing Fig. 1 is a view showing an installation of my relay in a residence wiring system; Fig. 2 is a sectional view through the relay showing it mounted in the junction box of a wiring system; Fig. 3 is a sectional view along the line 3-3 of Fig. 2; Fig. 4 is an exploded view of the relay mechanism; Fig. 5 is another view oi the relay mounted in position in the junction box of a wiring system, and Figs. 6 and 7 are views of a means for holding the relay in position in a junction box.

In many wiring systems, for example, in house lighting systems, it is desirable to provide a circuit arrangement which may be installed at low cost, which may be readily adaptable for the needs of a particular installation, and which may be flexible so that the system may be controlled from any number of conveniently located points. In ordinary residential installations now in use it is customary to wire the system from the lighting fixtures to the controlling switches with suitable high voltage cable such as armored or non-metallic sheathed cable, which is adapted to operate under the full voltage with which the system is supplied, for example, 110 volts. This means that long runs of high voltage cable must be made between the controlling switches and associated lighting fixtures, or the like, particularly, in the case where a lighting fixture is controlled from any one of a number of points; for example, a light which is controlled from the head and the foot of a stairway. Inasmuch as this type of cable is relatively high in cost these long runs of high voltage cable add to the expense of the installation and, in many cases, cause installation of lighting systems that are inadequate for the needs of the residence.

According to my invention these deficiencies may be overcome by employing a relay to operate the lighting ilxtures. or the like, and by operating it from any one of a number or points. It is contemplated that the relay be operated at a relatively low voltage as compared with the voltage required in operating the lighting circuit; for example, 16 volts, although other voltages may be used. This means that it is unnecessary to run high voltage cable from the relay to the control points or switches. Inasmuch as it is proposed to mount the relay in a junction box of the wiring system adjacent the controlled lighting iixture, a great deal of 'expense is saved in wiring the system inasmuch as low voltage conductors, for example. bell wire, may be run from the relay to the controlling switches. Furthermore, the relay system is so designed that an unlimited number of controlling switches may be used. 'I'his makes it possible to control the relay and its associated lighting xture from any number of points. For example, it might be desirable to control a light in a garage of a residence from several points within the house and from a point outside the house. Not only may my relay be built into new wiring systems but it may be readily incorporated into existing systems simply by mounting it within the junction box of the system.

The relay is so designed that the high voltage contacts controlling the circuit to the associated lighting fixture are located within the junction box where they are segregated from low voltage terminals located outside the box. Moreover, the relay is so constructed that it may be mounted in a junction box simply by inserting it through one of the openings ordinarily provided in the box for the reception of armored cable or rigid conduit of a conventional wiring system.

Referring to Fig. 1 of the drawing my invention employs a relay i which is illustrated, by Way of example, as incorporated in a house wiring system including a lighting fixture 8 supported by a junction box 9 and operated by momentary contact switches i0, the lighting fixture being fed by current from a cable il operating at a relatively high voltage, for example volts. The switches i0 are wired to the relay by low voltage cable I2 such as ordinary bell wire and are operated by a current having a relatively low potential, for example, 16 volts. This may be obtained in any convenient manner, for example, from a transformer connected to the high voltage line i3 or from dry cell batteries. In any particular installation only one source of low voltage power is required. Fig. 1 illustrates two switches, each adjacent a door of a room so that the lighting xture 8 is controlled from two points. Manifestly, the number oi" switches may be increased or decreased at will.

As shown most clearly by Figs. 2, 3 and 5, the relay 'I is supported by a wall of the junction box 9 and is most conveniently mounted therein by inserting it through an opening 9' in the wall of the box; the opening is made by punching out one of the knockouts which are customarily formed in such junction boxes for the reception of rigid conduit, armored cable, or the like. To facilitate mounting of the relay within the opening 9' it is formed with a relatively large base portion I3 and a relatively narrower extension I4, the extension being inserted through the wall of the box and extending beyond the coniines thereof. That portion of the relay housing located within the box contains the contacts which are connected to the high voltage cable II, while that portion of the relay which extends outside the box contains the terminals and operating mechanism connected to the loW voltage wires I2 and the switches I8,

To this end, the base portion I3 comprises a housing I5 of insulating material, for example, a phenolic condensation product and iiller, the housing being provided with a recess I6 for the reception of spaced flexible contact blades I1. Each blade I1 is secured in any suitable manner, for example, by spot welding, to a relatively rigid terminal plate I8 mounted in grooves I9 formed in the wall of the housing I5. The grooves I9 are spaced apart as shown most clearly by Fig. 3, so that the contact blades |1 extend into the recess I6 in spaced relationship. Each of the terminal plates I8 is provided with a terminal screw I8' for connection -to the conductors of the high voltage cable I3. Each contact blade is biased toward the other` so that the circuit through them is completed by permitting them to move toward each other for engagement at their outer ends, the circuit being completed through contact surfaces 20 which may be formed of any precious metal such as silver. 'Ihe outerv ends of the contact blades are bent inwardly toward each other so that engagement of the contact surfaces is effected by only a slight movement or exure of the contact blades. 'I'he contacts are moved to closed and open circuit positions in response to actuation of the switches I0.

Movement of the contact blades is effected by an operating mechanism including a cam member 2| having bearings 22 which rest in openings 23 formed in the contact blades so that the cam member is supported for rotation between the contact blades. In manufacture, the cam is made of molded insulating material. Each side of the cam member is formed with a plurality of hill and valley cam surfaces 24 which cooperate with projections 25 in the contact blades formed by punching in a portion of the metal. As the cam is rotated, the projections 25 follow the hill and valley coniigurations of the cam surfaces 24 so that the contact surfaces 2li make or break contact in accordance with the position of the cam surfaces 24. The circuit through the contact blades is moved from open to closed position or vice versa by rotating the cam 2| through an angle of approximately 45 degrees.

Rotation of the cam is eiected by means of operating fingers 26 and 21 which engage oneway cam surfaces 28 formed on the outer periphery of the cam member 2|, the iingers and earn cam member 2|.

asa-m44 surfaces forming, in efect. a, ratchet for movement of the cam member in step by step rotation. The fingers 25 and 2l extend beyond the confines of the recess I6 and are connected to a plunger 29 operated by a solenoid 30. In order to isolate the solenoid 30 and the low voltage portion of the system from the high voltage contacts Il the recess I6 is closed by a plate 3|, preferably formed of insulating material, such as sheet ber. The ngers 26 and 21 extend through openings 32 in the plate for cooperation with the In addition to separating the high and low voltage portions of the relay, the plate 3| guides the operating fingers 26 and 21 into engagement with the cam member and prevents these ngers as well as the plunger 29 from rotating within the body of the relay.

The operating solenoid 38 is mounted within the extension I4 which is formed of a sheet metal tubular casing or member 33 provided with flanges 34 for mounting it on the base I3. This is accomplished by any suitable fastening means, such as the drive pins 35, which also extend through the closure plate 3| to secure it in position. The tubular member 33 is made of such a size as to pass through the knock-out opening 9' and may be of the order of 7s of an inch in diameter. The casing 33 forms a chamber for housing the solenoid and operating plunger which is separated from the recess I6 containing the contacts l1 by the closure plate 3|. The solenoid comprises a winding of insulated wire on a drum 36 formed of insulating material and which is provided with a central opening 31 for the reception of the plunger 29. The drum is secured in position in the extension member by means of spaced metal plates 38 and 39, the plate 39 being held in position by lndentations 40 formed in the wall of the casing while the plate 38 is secured in position in the casing by engagement with spaced insulating plates 40' and 4| held in position by a lip 42 on the end of the casing. The lead lines from the windings extend through openings 43 in the plates 38 and 48' and are then fastened in any suitable manner to terminal plates 44 mounted in the outer insulating plate 4|. The terminals plates 44 are provided with terminal screws 45 for connection to the low voltage wires running to the switch I0. This structure provides a rigid assembly for holding the solenoid securely Within the casing 33 so that it may operate the contact cam member 2| through the medium of the plunger 29.

The plunger 29 slides within the opening 31 in the center of the solenoid; it is fonned of two semi-circular members 46 separated by an air gap 41 to reduce eddy currents through the plunger. These members are secured together at one end by means of a steel armature plate 48 locked between a copper ring 49 and steel washer 49' on one side of the plate and a steel washer 50 on the other side, the ends of the semi-circular members 46 being peened over as shown at 5| to secure the assembly together. The armature 48 is provided with ears 52 at each end facing the solenoid 30 which cooperate with the solenoid in pulling the plate toward it when the solenoid is energized by actuation of one of the switches I0. During energization of the solenoid the copper disk 49 in conjunction with the valternate magnetic paths provided by Washer 49 and plate 52 acts as a pole shader to reduce the noise inherent in a solenoid operated by alternating current. After deenergization of the solenoid the plunger is moved to outward position by a coil spring 54 located in the space between the semicircular members 46 in the interior of the plunger and biased between the plate 38 and the closed end of the plunger. The actuating ngers 26 and 21 form the arms of a U-shaped metal strip clamped between the armature plate 48 and the washer 50 in the manner illustrated by Fig. 2. Lateral movement of the plunger is limited in one direction by simultaneous engagement of washer 49' and of the ears 52 of plate 48 with the plate 88 of the solenoid, while movement in the other direction under the innuence of the spring 54 is limited by the closure plate 8l.

When the plunger. moves to the left in the showing of Fig. 2 the lower operating finger 21 engages one of the cam surfaces 28 and rotates the cam member through an angle of approximately 33 degrees opening or closing the contacts 2li as the case may be and upon deenergization of the solenoid the spring 84 moves the plunger to the right to its initial position at which time the upper member 28 likewise engages one oi' the cam surfaces 28 and moves the cam member through an additional angle oi' approximately 12 degrees thereby making a total angular movement of approximately 45 degrees or 1/5 revolution for one operation of the solenoid in response to a single actuation oi' one of the switches l0.

Actuation of the plunger rotates the cam member 2| and causes it to open or close the contacts 20 in sequence as the case may be. If the contacts are in closed position so that the light 8 is on, operation of either one of the switches I8 will energize the solenoid and cause it to move the contacts to open position. Similarly, when the light is oil," it may be lighted by operating either one ot the switches i0. This means that the light is turned either "ofP or on" in response to a single actuation of the relay and since the relay may be controlled from any number of points, it will be apparent that operation oi the light from a number of points does not require a complicated wiring system.

One of the advantages of my invention is that it may be applied to existing wiring systems without effecting any substantial changes or alterations in the system simply by inserting it in the junction box customarily embodied in the system. Thereafter, the contact blades I1 are electrically connected in series with the high voltage cable i8 and the electrical fixture to be controlled and the solenoid is connected to the low voltage wires and thence to one or more operating switches Il. The wires I2 running to the operating switches may be of small diameter insulated bell wire and these are very easy to install and are unobtrusive in appearance. The switches Il may be of an extremely simple type such as an ordinary push button switch inasmuch as the voltage and current through the switch are relatively low. It is not necessary to employ relatively costly switches. capable of interrupting relatively large amounts of current. By my construction the high voltage contact members are completely enclosed within an insulating housing formed by the recess Il. In addition, these contact members and their associated terminals are likewise enclosed within the Junction box I so that the high voltage portion oi the system is completely separated from the low voltage portio A person operating one of the switches l0, cannot, therefore be subjected to a dangerous shock from the high voltage system.

As pointed out in the preceding paragraphs the relay is mounted in position simply by inserting it through a knockout opening in the junction box; it is held in this position, as shown by Figs. 6 and 7, by a bowed spring member 55 mounted within the tubular casing 33, the ends of which project through openings 56 in the walls of the casing. 'Ihe ends of the spring member are provided with beveled surfaces 51 so that as the relay is passed through the opening l2 the beveled surfaces engage the Walls of the junction box and are flexed inwardly to permit the relay to be seated in position; thereafter they are snapped outwardly by the tension in the bowed spring member and engage the outer wall of the outlet box to lock the relay in position. This provides a ready and easy means of mounting the relay since it may be simply snapped into position in the opening 8'.

As shown by Fig. 5, my relay is extremely compact and takes up only a small portion of the space available in an ordinary llunction box. This is made possible by positioning the solenoid operating mechanism outside the junction box; this construction has the further advantage that the low voltage circuit to the solenoid is separate from the high voltage lighting circuit. Compactness of structure is further attained by mounting the contact-operating cam between the contacts and by providing a small amount of travel of the flexible blade contacts to control the circuit therethrough.

What I claim as new and desire to secure by Letters Patent of the United States is:

l. In a relay, a housing. spaced flexible contacts mounted in said housing and a cam member of insulating material supported by and between said contacts, the contacts and cam being provided with cooperating cam surfaces and follower elements for controlling a circuit through said contacts upon rotation of said cam.

2. In a relay, a housing, flexible contact blades mounted in said housing in opposed spaced relationship, a cam member of insulating material mounted between and supported for rotation upon said contact blades. the opposite sides of said cam member being provided with cam surfaces engaging said contact blades for flexing them toward and away from each other to control a circuit therethrough, the outer periphery of said cam member being of annular formation provided with stepped cam surfaces and spaced operating elements cooperating with said stepped cam surfaces on opposite sides of the cam member for rotating said member in a step by step manner.

3. In a relay, spaced iiexible contacts mounted in opposed relationship, a cam member of insulating material rotatably supported by and between said contact blade the opposite sides oi said cam member being formed with cam surfaces cooperating with said contact blades to ilex them toward and away from each other upon rotation of said cam member to open and close a circuit through said contacts and driving means for moving said cam in step by step rotation.

PHILIP HUTI. 

